Aqueous solutions of optical brighteners

ABSTRACT

The instant invention relates to storage stable aqueous solutions of stilbene optical brighteners with polyvinyl alcohols which can be directly used by the papermaker in that they may be diluted with water and/or be metered directly into a coating composition, to provide coated papers of a particularly high whiteness.

CROSS REFERENCE TO RELATED APPLICATIONS

This application is a continuation application of U.S. patent application Ser. No. 11/918,188 (filed Oct. 9, 2007), which is a 371 National Stage of PCT/EP2006/061329 (filed Apr. 5, 2006), which claims priority to EP 05007691.8 (filed Aug. 4, 2005) the contents of all are incorporated herein by reference in their entirety.

The instant invention relates to storage stable aqueous solutions of stilbene optical brighteners with polyvinyl alcohols which can be directly used by the papermaker.

It is well known that the whiteness and thereby the attractiveness of coated papers can be improved by the addition of optical brighteners to the coating slip. In order to satisfy the demand for coated papers of higher whiteness, there is a need for more efficient optical brighteners.

WO 96/00221 discloses tetrasulphonated stilbene brighteners derived from amino acids for use in paper, textiles and detergents. Polyvinyl alcohols are included in a list of additives which are said to boost the performance of brighteners when applied to the surface of paper.

WO 98/42685 discloses hexasulphonated stilbene brighteners made by using certain amino acids, disclaiming the compounds of WO 96/00221. Also described is a method for the fluorescent whitening of a paper surface by applying the brightener as part of a pigmented coating composition which also comprises polyvinyl alcohol as a water-soluble co-binder or protective colloid.

EP 1355004 describes the use of certain stilbene brighteners which are not derived from amino acids for brightening aqueous coating slips comprising at least one latex binder and at least one synthetic co-binder differing therefrom. Polyvinyl alcohols are cited as being preferred synthetic co-binders.

Japanese Kokai 62-106965 discloses certain hexasulphonated stilbene brighteners derived from amino acids. The brighteners are claimed to be very effective for the fluorescent whitening of paper, and may be applied to the paper surface as part of a sizing solution or a pigmented coating composition. Polyvinyl alcohol is mentioned as a possible component of the sizing solution.

Even though it is known from the prior art that polyvinyl alcohol, among other compounds, can boost the brightening performance, until now the papermaker, when wanting to use said alcohol, has had to add it separately to the coating slip. Therefore a need still exists to simplify the process of preparing brightened, coated papers.

It has now surprisingly been found that it is possible to produce storage stable solutions consisting essentially of a stilbene optical brightener and a polyvinyl alcohol which may be used directly by the papermaker, in that they may be diluted with water and/or be metered directly into a coating composition, to provide coated papers of a particularly high whiteness.

The invention thus provides aqueous optical brightener solutions consisting essentially of

(a) at least one optical brightener of formula (1)

-   -   in which     -   M is hydrogen, an alkali metal atom, ammonium or a cation         derived from an amine, preferably hydrogen or sodium, most         preferably sodium,     -   n is 1 or 2, and         X is a natural or unnatural amino acid from which a hydrogen         atom of the amino group has been removed;         (b) polyvinyl alcohol having a degree of hydrolysis greater than         75% and a Brookfield viscosity of 2-40 mPa·s (4% w/w aqueous         solution at 20° C.); and the optical brightener is         advantageously in the range 6 to 60%, preferably 10 to 50% by         weight of the solution.

The pH of the aqueous solutions is preferably from neutral to clearly alkaline, in particular in the range pH 7 to pH 10. The pH may, if necessary, be adjusted by addition of M-corresponding bases, e.g. alkali metal hydroxides or carbonates, ammonia or amines.

The optical brightener solutions of the invention are storage-stable and may be used directly as such, in that they may be diluted with water and/or be metered directly into a coating composition. Thus a further object of the invention is the addition of the brightener solutions to coating compositions in order to obtain a coated and optically brightened paper.

Thus, the invention also provides a process for the production of coated paper that is optically brightened at least in the coating, wherein a coating composition as described above is coated onto paper after sheet formation.

The coating compositions are essentially aqueous compositions that contain at least one binder and a white pigment, in particular an opacifying white pigment, and may additionally contain further additives such as dispersing agents and defoamers.

Although it is possible to produce coating compositions that are free from white pigments, the best white substrates for printing are made using opaque coating compositions that contain 10-70% white pigment by weight. Such white pigments are generally inorganic pigments, e.g., aluminium silicates (kaolin, otherwise known as china clay), calcium carbonate (chalk), titanium dioxide, aluminium hydroxide, barium carbonate, barium sulphate, or calcium sulphate (gypsum).

The binders may be any of those commonly used in the paper industry for the production of coating compositions and may consist of a single binder or of a mixture of primary and secondary binders. The sole or primary binder is preferably a synthetic latex, typically a styrene-butadiene, vinyl acetate, styrene acrylic, vinyl acrylic or ethylene vinyl acetate polymer. The secondary binder may be, e.g., starch, carboxymethylcellulose, casein, soy polymers, or polyvinyl alcohol.

The sole or primary binder is used in an amount typically in the range 5-25% by weight of white pigment. The secondary binder is used in an amount typically in the range 0.1-10% by weight of white pigment.

The optical brightener of formula (1) is used in an amount typically in the range 0.01-1% by weight of white pigment, preferably in the range 0.05-0.5% by weight of white pigment.

EXAMPLES

The following examples shall explain the instant invention in more detail. If not indicated otherwise, “%” and “parts” are by weight; viscosities are measured on a 4% aqueous solution at 20° C. using a Brookfield viscometer.

Preparative Example 1A

Optical brightener solution 1a is produced by stirring together

-   -   13.1 parts (0.01 mol) of an optical brightener of formula (4),     -   6.3 parts of a polyvinyl alcohol having a degree of hydrolysis         of 98.5% and a Brookfield viscosity of 2.75 mPa·s, and     -   80.6 parts of water         while heating to 90-95° C., until a clear solution is obtained         that remains stable after cooling to room temperature. The pH of         the solution is adjusted to 9.0 with sodium hydroxide.

Preparative Example 1C

Comparative Example (without Polyvinyl Alcohol)

Optical brightener solution 1c is produced by stirring together

-   -   15.1 parts (0.01 mol) of an optical brightener of formula (5),         and     -   84.9 parts of water. The pH of the solution is adjusted to 9.0         with sodium hydroxide.

Preparative Example 1D

Comparative Example Representing the State-of-the-Art (EP 1355004)

Optical brightener solution ld is produced by stirring together

-   -   12.2 parts (0.01 mol) of an optical brightener of formula (6),     -   6.3 parts of a polyvinyl alcohol having a degree of hydrolysis         of 98.5% and a Brookfield viscosity of 2.75 mPa·s, and     -   81.5 parts of water         while heating to 90-95° C., until a clear solution is obtained         that remains stable after cooling to room temperature. The pH of         the solution is adjusted to 9.0 with sodium hydroxide.

Preparative Example 2A

Optical brightener solution 2a is produced by stirring together

-   -   13.1 parts (0.01 mol) of an optical brightener of formula (4),     -   6.3 parts of a polyvinyl alcohol having a degree of hydrolysis         of 85% and a Brookfield viscosity of 3.7 mPa·s, and     -   80.6 parts of water         while heating to 90-95° C., until a clear solution is obtained         that remains stable after cooling to room temperature. The pH of         the solution is adjusted to 9.0 with sodium hydroxide.

Preparative Example 2B

Optical brightener solution 2b is produced by stirring together

-   -   15.1 parts (0.01 mol) of an optical brightener of formula (5),     -   6.3 parts of a polyvinyl alcohol having a degree of hydrolysis         of 85% and a Brookfield viscosity of 3.7 mPa·s, and     -   78.6 parts of water     -   while heating to 90-95° C., until a clear solution is obtained         that remains stable after cooling to room temperature. The pH of         the solution is adjusted to 9.0 with sodium hydroxide.

Preparative Example 2C

Comparative Example (Without Polyvinyl Alcohol)

Optical brightener solution 2c is produced by stirring together

-   -   15.1 parts (0.01 mol) of an optical brightener of formula (5),         and     -   84.9 parts of water. The pH of the solution is adjusted to 9.0         with sodium hydroxide.

Preparative Example 2D

Comparative Example Representing the State-of-the-Art (EP 1355004)

Optical brightener solution 2d is produced by stirring together

-   -   12.2 parts (0.01 mol) of an optical brightener of formula (6),     -   6.3 parts of a polyvinyl alcohol having a degree of hydrolysis         of 85% and a Brookfield viscosity of 3.7 mPa·s, and     -   81.5 parts of water         while heating to 90-95° C., until a clear solution is obtained         that remains stable after cooling to room temperature. The pH of         the solution is adjusted to 9.0 with sodium hydroxide.

Preparative Example 3A

Optical brightener solution 3a is produced by stirring together

-   -   18.9 parts (0.0125 mol) of an optical brightener of formula (5),     -   1.2 parts of a polyvinyl alcohol having a degree of hydrolysis         of 85% and a Brookfield viscosity of 3.7 mPa·s, and     -   79.9 parts of water         while heating to 90-95° C., until a clear solution is obtained         that remains stable after cooling to room temperature. The pH of         the solution is adjusted to 9.0 with sodium hydroxide.

Preparative Example 3B

Comparative Example (Without Polyvinyl Alcohol)

Optical brightener solution 3b is produced by stirring together

-   -   18.9 parts (0.0125 mol) of an optical brightener of formula (5),         and     -   81.1 parts of water. The pH of the solution is adjusted to 9.0         with sodium hydroxide.

Application Example 1

A coating composition is prepared containing 500 parts chalk (commercially available under the trade name Hydrocarb 90 from OMYA), 500 parts clay (commercially available under the trade name Kaolin SPS from IMERYS), 470 parts water, 6 parts dispersing agent (a sodium salt of a polyacrylic acid commercially available under the trade name Polysalz S from BASF), 200 parts latex (an acrylic ester copolymer commercially available under the trade name Acronal S320D from BASF) and 50 parts of a 10% solution of carboxymethyl cellulose (commercially available under the trade name Finnfix 5.0 from Noviant) in water. The solids content is adjusted to 60% by the addition of water, and the pH is adjusted to 8-9 with sodium hydroxide.

Solutions 1a, 1b, 1c and 1d, made as described in Preparative Examples 1A, 1B, 1C and 1D respectively, are added at a range of concentrations from 0.5 to 4.0% to the stirred coating composition. The brightened coating composition is then applied to a commercial 75 gsm neutral-sized white paper base sheet using an automatic wire-wound bar applicator with a standard speed setting and a standard load on the bar. The coated paper is then dried for 5 minutes in a hot air flow. The dried paper is allowed to condition, then measured for CIE Whiteness on a calibrated Elrepho spectrophotometer.

TABLE 1 CIE White- CIE White- CIE White- CIE White- ness using ness using Conc. of ness using ness using Soln. 1c Soln. 1d Soln. (%) Soln. 1a Soln. 1b (Comparative) (Comparative) 0 89.1 89.1 89.1 89.1 0.5 100.7 101.3 98.3 98.3 1.0 107.2 106.4 101.6 104.6 2.0 114.2 114.2 109.3 110.9 4.0 118.9 121.4 114.7 117.5

Application Example 2

Application Example 1 is repeated using Solutions 2a, 2b, 2c and 2d, made as described in Preparative Examples 2A, 2B, 2C and 2D respectively.

TABLE 2 CIE White- CIE White- CIE White- CIE White- ness using ness using Conc. of ness using ness using Soln. 2c Soln. 2d Soln. (%) Soln. 2a Soln. 2b (Comparative) (Comparative) 0 89.1 89.1 89.1 89.1 0.5 98.2 98.3 98.3 97.9 1.0 106.8 104.3 101.6 102.2 2.0 111.2 110.5 109.3 108.0 4.0 114.8 118.1 114.7 112.8

Application Example 3

A coating composition is prepared containing 500 parts chalk (commercially available under the trade name Hydrocarb 90 from OMYA), 500 parts clay (commercially available under the trade name Kaolin SPS from IMERYS), 370 parts water, 6 parts dispersing agent (a sodium salt of a polyacrylic acid commercially available under the trade name Polysalz S from BASF), 200 parts latex (an acrylic ester copolymer commercially available under the trade name Acronal S320D from BASF) and 400 parts of a 20% solution of an anionic potato starch (Perfectamyl A4692 from AVEBE B.A.) in water. The solids content is adjusted to 60% by the addition of water, and the pH is adjusted to 8-9 with sodium hydroxide.

Solutions 3a and 3b, made as described in Preparative Examples 3A and 3B respectively, are added at a range of concentrations from 0.5 to 4.0% to the stirred coating composition. The brightened coating composition is then applied to a commercial 75 gsm neutral-sized white paper base sheet using an automatic wire-wound bar applicator with a standard speed setting and a standard load on the bar. The coated paper is then dried for 5 minutes in a hot air flow. The dried paper is allowed to condition, then measured for CIE Whiteness on a calibrated Elrepho spectrophotometer.

TABLE 3 CIE Whiteness Conc. of CIE Whiteness using Soln. 3b Soln. (%) using Soln. 3a (Comparative) 0 87.9 87.9 0.5 99.4 98.2 1.0 106.4 104.9 2.0 114.8 112.1 4.0 123.2 120.8

The instant results clearly show the surprising superiority in whiteness of the instant solutions containing polyvinyl alcohol. 

1. An aqueous optical brightener solution consisting essentially of (a) at least one optical brightener of formula (1)

wherein M is hydrogen, an alkali metal atom, ammonium or a cation derived from an amine, N is 1 or 2, and X is a natural or unnatural amino acid from which a hydrogen atom of the amino group has been removed; (b) a polyvinyl alcohol having a degree of hydrolysis greater than 75% and a Brookfield viscosity of 2-40 mPa·s; and (c) water.
 2. An aqueous optical brightener solution according to claim 1 wherein M is hydrogen or sodium, n is 1 or 2, X is aspartic acid, glutamic acid or iminoacetic acid, and wherein the polyvinyl alcohol has a degree of hydrolysis of greater than or equal to 80% and a Brookfield viscosity of 2-20 mPa·s
 3. An aqueous optical brightener solution according to claim 1 wherein the weight ratio of the polyvinyl alcohol to the optical brightener is from 0.01:1 to 1.5:1 and wherein the concentration of the optical brightener is from 6 to 60% by weight.
 4. An aqueous optical brightener solution according to claim 1 wherein the weight ratio of the polyvinyl alcohol to the optical brightener is from 0.03:1 to 1:1 and wherein the concentration of the optical brightener is from 10 to 50% by weight.
 5. A paper coated with a coating composition comprising an aqueous optical brightener solution according to claim
 1. 6. A process for the production of a coated paper comprising the step of coating a coating composition comprising a solution according to claim 1 onto the paper after sheet formation.
 7. A process according to claim 6 wherein the coating composition comprises from 10 to 70% by weight of one or more white pigments.
 8. A process according to claim 7 wherein the coating composition contains a primary binder based on synthetic latex, wherein the primary binder is selected from the group consisting of: styrene-butadiene, vinyl acetate, styrene acrylic, vinyl acrylic and ethylene vinyl acetate polymer and optionally a secondary binder selected from the group consisting of starch, carboxymethylcellulose, casein, soy polymers, and polyvinyl alcohol.
 9. A process according to claim 8 wherein the primary binder is used in an amount from 5 to 25% by weight of the one or more white pigments, wherein the secondary binder is used in an amount from 0.1 to 10% by weight of the one or more white pigments and wherein the optical brightener of formula (1) is used in an amount from 0.01 to 1% by weight of the one or more white pigments.
 10. The aqueous optical brightener solution according to claim 1, further comprising up to 10% by weight of salt, wherein the salt is a by-product from the production of the optical brightener.
 11. The aqueous optical brightener solution according to claim 1, further comprising one or more antifreezes, biocides, or complexing agents.
 12. A process according to claim 9 wherein the optical brightener of formula (1) is used in an amount from 0.05 to 0.5% by weight of the one or more white pigments.
 13. The aqueous optical brightener solution according to claim 1, further comprising one or more organic by-products formed during the preparation of the optical brightener. 